Mechanical Design Engineering

I have 40-years experience working in Mechanical Design using 3D software: SolidWorks; AutoCad Inventor; Siemens NX; Pro/Engineer Wildfire; TurboCad. - 2D software: AutoCad. - Additional software: SolidWorks Simulation; Inventor Nastran; FEMAP, Flowtherm; Pro/NC; Vault; PDM; MRP; Visual Studio.

Industries I have worked in: Military; Satellite Communications; Naval; Flight Simulators; Engines; Vacuum chambers; Robotics; Automation; sub-sea; optics; manufacturing support; space.

Manufacturing techniques I have used are: Sheet metal; castings; steel structures; welding; precision machining; extrusions; pultruding; plastic injection moulding; vac-forming; CFRP; harsh environments (explosive; vacuum; severe vibration; shock; rapid decompression; constant thermal cycling; corrosive.).

My experience covers all aspects of the project from initial concept, with the creation of storyboards for customer approval, through Research and Development, design, detailing, analysis (FEA), sub-contract liaison, assembly management, test and final hand-over.

Additional knowledge I have: RF ('C', 'X', 'Ku', 'Ka' bands); EMC; electronics; software; testing.

Analysis: Modal; Vibration; Stress; Static and Dynamic Thermal

Test experience: Vibration; shock; Thermo Vacuum; friction; Quasi-static.

I have an excellent understanding of tolerancing (GD+T), but more importantly, where critical tolerances should and should not be used because tolerances cost money as well as saving it. I always consider my designs with respect to manufacturability, assembly and use.

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Space System Engineering

The Systems manager in the space industry works alongside the project manager, responsible for the technical side of the project.

The first task is to generate the Verification control document (VCD) which will list all of the technical requirements for the project, and will cross-reference to the documents which qualify the requirements. One of the systems managers tasks is also to determine feasibility of the requirements.

The next task is to ensure all members of the team are aware of the requirements that they have to satisfy. The Design Description (DDF) and Design Justification (DJF) documents are produced along with a Test Plan (TPL). Once the team is happy with the initial designs, a Preliminary Design Review (PDR) is held with the customer. This gives everyone the opportunity to review the design and make necessary changes.

Once PDR has been passed, 3D models and drawings are finalised along with an ICD, modal and stress analasis reports (ARP) and Test Procedures (TPR). A Critical Design Review (CDR) is held with the customer to review the final design.

Once CDR has been approved, manufacturing can commence. Close attention is made to material traceability and tolerance conformance.

During assembly, some testing can be performed such as friction for bearings, and fastener loading. Once the complete assembly has been built, a Pre-Test REview (PTR) is held with the customer to review the assembly and check test procedures.

Testing is rigorous. There are two methods for achieving space-flight qualification. One is to use an Engineering Qualification Model (EQM), where an identical unit to the Flight Model (FM) is tested to higher levels and timescales than the real levels, and then the FM is tested to the real levels and results compared. The other method is to use the ProtFlight method (PFM) in which a single unit is tested to the higher EQM levels, but at the shorter FM timescales. This unit then becomes the FM.

Once testing is complete, and assuming everything passes, the the Final Report (FR) is generated which details all the testing and results, and any deviations to the initial requirements that have customer approval. Space-Flight Qualification can then be given.

Nothing can compare to watching your first launch that you have been involved with, especially when so much dedication has been put in to the project. I worked as Systems Manager on Sentinel 1a and 1b, Sentinel 3a and 3b, and a GSTP, and as space mechanisms specialist on ExoMars and Solar Orbiter.I became the department vibration and shock specialist and we designed and built our own ringin-plate shock table.

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